Busbar Manufacturing
At Datum, we specialise in custom, thin metal, busbar manufacturing, delivering precision copper, aluminium, nickel and nickel plated steel busbars for high-voltage battery systems, including EV batteries, switchgear, control panels, fuse gear and transformers. From prototype development to full-scale production, our state-of-the-art laser, cnc machining and stamping facilities ensure precision and efficiency.
Busbar Manufacturing
Our laser cutting process enables the precise production of electrical busbar systems with high accuracy and repeatability, ensuring that each component meets exact specifications. By integrating advanced laser cutting technology into our busbar assembly solutions, we create intricate designs and shapes that enhance efficiency and reliability within high-voltage battery systems.
- Expertise in multi cell busbar fabrication for switchgear, control panels, and transformers.
- Advanced laser & stamping facilities – Precision manufacturing for custom busbar fabrication.
- Prototype to full-scale production – Supporting projects of all sizes with rapid prototyping and scalable production.
- Industry-leading quality & reliability – Ensuring durable, high-performance busbars for critical power applications.
Custom Busbars
At Datum, we specialise in the design and manufacturing of custom busbars, tailored to meet the unique requirements of high-voltage applications. Using advanced laser cutting, stamping, and precision machining technologies, we create copper, aluminium, nickel and nickel plated steel busbars that ensure optimal current distribution, heat management, and mechanical stability. Our expertise in custom busbar fabrication allows us to develop innovative, space-saving designs that seamlessly integrate into battery packs, switchgear, control panels, and power distribution systems providing maximum efficiency and reliability to the battery pack. Our team of experts can work with clients to create custom solutions that meet their specific requirements.
busbar Stamping, Bending & Punching
- Punching: The stamping machine punches the shape from the surrounding material.
- Blanking: Blanking involves cutting out the precise shape from a flat sheet metal material.
- Embossing: Embossing is the process that creates raised and shallow features onto the material.
- Bending: The metal is bent in one direction and repeated to create a specific shape.
Why Busbars Are Essential for High-Voltage Battery Packs
High-voltage battery packs, require busbars for several critical reasons:
Efficient Current Distribution
In high-voltage battery systems, large amounts of current must be transmitted efficiently. Our low-resistance, high-conductivity busbars ensure minimal power loss, maximising system efficiency.
Superior Heat Management
Made from highly conductive materials like copper, aluminium, nickel and nickel plated steel, our busbars efficiently dissipate heat, preventing overheating and reducing the risk of component failure.
Enhanced Mechanical Stability & Safety
Busbars provide a rigid, durable electrical connection, reducing the risk of loose connections, arcing, or fire hazards in high-power applications.
Space Optimisation & Compact Design
In high-voltage battery packs, space efficiency is critical. Our custom busbar designs allow for a compact, layered arrangement, optimising both space and performance.
Seamless Integration with Battery Management Systems (BMS)
Busbars can include built-in voltage and temperature sensors for real-time monitoring. This improves battery management, preventing overcharging, overheating, or imbalances in high-voltage systems.
Busbar Applications
Power distribution:
Busbars are used to distribute electricity in switchgear, panel boards, and busway enclosures.High voltage equipment:
Busbars are used to connect high voltage equipment at electrical switchyards.Battery banks:
Busbars are used to connect low-voltage equipment in battery banks.Busbar - Industry Sectors
Busbars are widely used across multiple industries due to their efficiency in power distribution, heat management, and space optimisation. Key industries include:
Electric Vehicles (EVs)
Used in EV battery packs, power distribution units, and charging infrastructure for efficient energy transfer and thermal management.
Renewable Energy
Essential in solar power systems, wind turbines, and energy storage solutions to connect and distribute electricity effectively
Electrical & Power Distribution
Found in switchgear, circuit breakers, transformers, and control panels to manage high-power electrical systems.
Aerospace & Defence
Used in aircraft power systems, satellites, and military-grade battery packs where lightweight and high-performance busbars are crucial.
Data Centres & Telecommunications
Helps in power distribution units (PDUs) and backup battery systems to ensure stable energy supply in critical operations.
Industrial Manufacturing & Automation
Supports robotics, CNC machinery, and high-power industrial equipment by providing reliable electrical connections.
Quality Control
Our Quality Control department performs robust quality checks. Datum is ISO 9001 certified.
Why Choose Datum?
Quality
Oil, grease and scratch free foils and components, produced to tight tolerances
Experience
With decades of experience, Datum leads the way in innovation and technology development
Efficiency
Rapid prototyping and production, short lead times and fast delivery
Precision
Our tolerance controls ensure you receive precision foils and components